Method for improving ohmic-contact behaviour between a contact grid and a emitter layer of a silicon solar cell

ABSTRACT

The invention relates to a method for improving the ohmic-contact behaviour between a contact grid and an emitter layer of a silicon solar cell. The object of the invention is to propose a method for improving the ohmic-contact behaviour between a contact grid and an emitter layer of a silicon solar cell, in which the effects on materials caused by irradiation of the sun-facing side are further minimized. In addition, the method should also be applicable to silicon solar cells in which the emitter layer has a high sheet resistance. This object is achieved by first providing the silicon solar cell with the emitter layer, the contact grid and a rear contact, and electrically connecting the contact grid to one pole of a voltage source, then a contacting device that is electrically connected to the other pole of the voltage source is connected to the rear contact, and with the voltage source, a voltage is applied directed contrary to the forward direction of the silicon solar cell that is less than the breakdown voltage of the silicon solar cell and, when applying this voltage, a point light source is guided over the sun-facing side of the silicon solar cell and thereby a section of a subsection of the sun-facing side is illuminated and thus a current flow is induced in the subsection where the current flow relative to the section has a current density of 200 A/cm 2  to 20,000 A/cm 2  and acts on the subsection for 10 ns to 10 ms.

The invention relates to a method for improving the ohmic-contactbehaviour between a contact grid and an emitter layer in a silicon solarcell.

When creating contacts in a crystalline solar cell, a screen-printingtechnique is used to apply a metal paste in the form of a contact gridto the front side of the cell, which is coated with dielectric siliconnitride. After application, the metal paste is baked into the siliconnitride at 800-900° C. and thus forms an electrical contact to theemitter layer. The process control during the baking in of the metalpaste has a critical influence on the contact formed, whereby faultyprocess control leads to high contact resistance at the transitionbetween the metal paste and the emitter layer in the silicon solar cell.High contact resistances can then result in a reduced efficiency of thesilicon solar cell.

Within the prior art, methods are known that permit the efficiencystabilization or performance improvement of solar cells. DE 10 2011 056843 A1, for example, describes a method for “stabilization of anefficiency of silicon solar cells”. In this, during the laminationprocess, a continuous flow of current is applied to a solar-cellassembly, which causes essentially boron—oxygen complexes to be brokendown in the silicon material.

U.S. Pat. No. 4,166,918 A proposes a method for improving theperformance of a solar cell, wherein the solar cell is subjected to avoltage applied contrary to its forward direction. In this case, acurrent flow is stimulated along short circuits within the solar cell,which causes them to be “burnt out” and thus eliminated.

These known methods have no known impact on the transition between thecontact grid and emitter layer of a silicon solar cell.

To produce low-resistance electrical contacts to the emitter layer, lowfilm resistances (less than 100 Ω/sq) are required in the emitter layer.However, this leads to a poor conversion of short-wave light intoelectricity. Better conversion is achieved with sheet resistances in therange of 110-150 Ω/sq, Here, however, only relatively high-impedancetransitions between contact grid and emitter layer can be generated viathe usual baking-in processes. To get around that, the concept of theselective emitter has been developed (for example, EP 2 583 315 B1).Here, the areas of the emitter layer that will subsequently be printedwith the metal paste are locally doped to a higher degree so that thesheet resistance is locally lowered. This, however, requires expensiveadditional steps in the process for producing silicon solar cells.

From the field of electronic components, it is known from DD 250 247 A3that the ohmic-contact behaviour towards semiconductor bodies that havebeen contacted by means of electrically conductive adhesive can beimproved by applying a voltage pulse. The mode of action of the contactimprovement is not described in further detail in the document. Theelectrically conductive adhesives used for contacting consistessentially of electrically conductive particles, usually silver ballsor silver flakes, which are surrounded by a polymer matrix.

German patent application DE 10 2016 009 560.1, which has not yet beenpublished, proposes a method for improving the ohmic-contact behaviourbetween a contact grid and an emitter layer in a silicon solar cell. Inthis case, the contact grid of a silicon solar cell is contacted with acontact-pin matrix, and a current flow is generated between the latterand the rear contact of this solar cell by means of voltage pulses. Withpulse durations between 1 ms and 100 ms and induced currents in therange of 10-to-30 times the short-circuit current of the silicon solarcell, a high contact resistance between the contact grid and the emitterlayer can be reduced and thus, for example, a faulty process controlwhile baking in the metal paste can thus be corrected. Alternatively, amethod is described, in which an electrically biased silicon solar cellis scanned with a point light source, whereby a current flow with ashort-circuit current density of 10-to-30 times that of the siliconsolar cell is generated in an illuminated subsection, Depending on thetype and quality of the silicon solar cell, in certain configurations,irradiation of the sun-facing side of the silicon solar cell can causeunwanted effects on materials or even material damage.

The object of the invention is to develop the method for improving theohmic-contact behaviour between a contact grid and an emitter layer of asilicon solar cell in such a way that the effects on materials caused byirradiation of the side facing the sun are further minimized. Inaddition, the method should also be applicable to silicon solar cells inwhich the emitter layer has a high sheet resistance.

This object is achieved by first providing a silicon solar cell with anemitter layer, a contact grid and a rear contact, and electricallyconnecting the contact grid to one pole of a voltage source. The otherpole of the voltage source is electrically connected to a contactingdevice, which is placed on the rear contact. The voltage source thenapplies a voltage that is directed contrary to the forward direction ofthe silicon solar cell and that is lower in magnitude than the breakdownvoltage of the silicon solar cell. When this voltage is applied, a pointlight source is then guided over the sun-facing side of the siliconsolar cell and, in the process, a section of a subsection of thesun-facing side is illuminated. Thus, a current flow is induced in thesubsection that, in relation to the section, has a current density of200 A/cm² to 20,000 A/cm² and acts on the subsection for 10 ns to 10 ms.

With the method according to the invention, faulty process controlduring the baking in of the metal paste are compensated for, so that thesolar cells nevertheless achieve their optimum serial resistance. Inaddition, with the method according to the invention, a very good ohmiccontact behaviour between the contact grid and the emitter layer isachieved, even with emitter layers that have high film resistances,meaning that the process steps necessary for forming a selective emittercan be omitted. Furthermore, by using the method according to theinvention, the baking-in process can be carried out at lowertemperatures, so energy can be saved in the process for producing thesilicon solar cell.

It is proposed that the point light source be a laser, a light-emittingdiode or a flash lamp.

In one embodiment, the point light source has a power density of 500W/cm² to 200,000 W/cm² on the section.

One version envisages that the point light source emit radiation of awavelength in the range from 400 nm to 1500 nm.

In a further embodiment, the section has an area in the range from 10³μm² to 10⁴ μm².

It is proposed that the voltage directed contrary to the forwarddirection of the silicon solar cell be in the range from 1 V to 20 V.

It is further proposed that the point light source be guided directlynext to contact fingers of the contact grid on the sun-facing side ofthe silicon solar cell.

In one version, the silicon solar cell has a monofacial or bifacialform.

In another version, the silicon solar cell has an n- or p-doped siliconsubstrate.

One embodiment envisages that the emitter layer have a sheet resistanceof more than 100 Ω/sq.

EMBODIMENTS OF THE INVENTION ARE EXPLAINED BELOW

First, a crystalline silicon solar cell is prepared. This has ananti-reflection layer of silicon nitride on its sun-facing side. Anemitter layer of the silicon solar cell is arranged below thisanti-reflection layer. On the sun-facing side, a front metallization isprinted in the form of a contact grid consisting of contact fingers andcollection contacts (busbars) made from a commercially available metalpaste (e.g., silver paste), which has been cured according to themanufacturer's specifications and baked into the silicon nitride layer.On the side facing away from the sun, the silicon solar cell is equippedwith a rear contact. This rear contact consists of a metallic layer,which can be designed either with passivation (PERO concept) or without.

The contact grid is electrically connected to one pole of a voltagesource. The other pole of the voltage source is connected to acontacting device, which is connected to the rear contact. The voltagesource then applies a voltage that is directed contrary to the forwarddirection of the silicon solar cell and that is lower in magnitude thanthe breakdown voltage of the silicon solar cell. When this voltage isapplied, a point light source is guided over the sun-facing side of thesilicon solar cell. The point light source can be, for example, a laser,a light-emitting diode or also the focused beam of a flash lamp. Theinvention is not limited to these radiation sources, however. The pointlight source emits radiation with wavelengths ranging from 400 nm to1500 nm. A section of a subsection of the sun-facing side of the siliconsolar cell is illuminated by this point light source, whereby a currentflow is induced in the subsection. The current flow has a currentdensity of 200 A/cm² to 20,000 A/cm² in relation to the section and actson the subsection for 10 ns to 10 ms.

The high current densities necessary for improving the ohmic-contactbehaviour between the contact grid and the emitter layer can be achievedby shifting the operating point of the illuminated cell area withoutcausing radiation-induced material damage. In the interaction betweenthe radiation density of the radiation source on the section, thecontact time and the applied voltage, the necessary current densitiesare achieved without the need for material-damaging irradiation. In thecase of an irradiated section with a surface diameter of approximately60 μm, currents with a magnitude of 50 mA to 600 mA are usuallygenerated at an applied voltage of 10 V, so that, based on the area ofthe irradiated section, a current density of around 200 A/cm² to 20,000A/cm² acts. The completely flowing currents are kept low particularly bythe relatively small area of the section receiving the rays.

Essentially, it is sufficient, when scanning the sun-facing side of thesilicon solar cell, that the point light source be moved directly to theleft and right of the contact fingers. Thus, the process times forprocessing a 6″ cell with the method according to the invention isaround one second.

In a further embodiment, the method according to the invention isapplied to silicon solar cells where the contact grids had been baked inat a temperature lower than that recommended by the manufacturer of themetal paste. Usually, the baking in takes place at temperatures around800° C. If the metal paste is baked in at a temperature of, for example,only 700° C., then the silicon solar cells have a high contactresistance at the transition between contact grid and emitter layer.Silicon solar cells of this type also exhibit an improvement of theohmic-contact behaviour between the contact grid and the emitter layerwith the method according to the invention. If the method according tothe invention and a baking-in process carried out at lower temperaturesare combined, the same contact resistance at the transition between thecontact grid and the emitter layer is achieved while at the same timesaving energy.

The method according to the invention is applicable both to monofacialand to bifacial silicon solar cells. For the latter, one-sided treatmentis sufficient to optimize the contacts on both sides.

In another embodiment, the treatment is applied to silicon solar cellswhere the emitter layers have not been selectively formed and that thushave a high sheet resistance (more than 100 Ω/sq) over the entiresurface. As described above, these silicon solar cells are also printedwith the metal paste and then subjected to a baking-in process, wherebythe baking-in process can also be carried out according to themanufacturer's instructions or at lower temperatures. After thebaking-in process, the silicon solar cells have only a comparativelyhigh value contact resistance at the transition between the contact gridand the emitter layer. With the application of the method according tothe invention, the contact resistance is likewise reduced in thesesilicon solar cells by the interaction of the radiation density of theradiation source on the section, the contact time and the appliedvoltage, and reduces the value necessary for the optimal operation ofthe silicon solar cell. A selective emitter is therefore not necessary,so the costly steps for its production can be omitted.

1-10. (canceled)
 11. A process for improving the ohmic-contact behaviorbetween a contact grid and an emitter layer in a silicon solar cell, theprocess comprising: providing the silicon solar cell with the emitterlayer, the contact grid and a rear contact; electrically connecting thecontact grid to one pole of a voltage source; electrically connecting acontacting device to another pole of the voltage source and to the rearcontact; applying a voltage with the voltage source directed contrary toa forward direction of the silicon solar cell that is less than thebreakdown voltage of the silicon solar cell; and, while applying thevoltage, guiding a point light source over one side of the silicon solarcell thereby, illuminating a section of a subsection of the one side andthus inducing a current flow in the subsection, where the current flowrelative to the section has a current density of 200 A/cm² to 20,000A/cm² and acts on the subsection for 10 ns to 10 ms.
 12. The process ofclaim 11, wherein the point light source is a laser, a light-emittingdiode, or a flash lamp.
 13. The process of claim 11, wherein the pointlight source demonstrates a power density of 500 W/cm² to 200,000 W/cm²on the section.
 14. The process of claim 11, wherein the point lightsource emits radiation with a wavelength in the range from 400 nm to1500 nm.
 15. The process of claim 11, wherein the section has an arearanging from 10³ μm² to 10⁴ μm².
 16. The process of claim 11, whereinthe voltage directed contrary to the forward direction of the siliconsolar cell ranges from 1 V to 20 V.
 17. The process of claim 11, whereinthe silicon solar cell is monofacial.
 18. The process of claim 11,wherein the silicon solar cell comprises an n-doped silicon substrate.19. The process of claim 11, wherein the emitter layer has a sheetresistance of more than 100 Ω/sq.
 20. The process of claim 11, whereinthe silicon solar cell is bifacial.
 21. The process of claim 11, whereinthe silicon solar cell comprises a p-doped silicon substrate.
 22. Theprocess of claim 11, wherein the one side is a sun-facing side of thesilicon solar cell.
 23. The process of claim 22, wherein the point lightsource is guided directly next to contact fingers of the contact grid onthe sun-facing side of the silicon solar cell.
 24. The process of claim11, wherein the one side is a rear side that is opposite to a sun-facingside of the silicon solar cell.
 25. A process for improving anohmic-contact behavior between a contact grid and an emitter layer in asilicon solar cell comprising: providing the silicon solar cell havingthe emitter layer, the contact grid, and a rear contact; electricallyconnecting the contact grid to one pole of a voltage source;electrically connecting a contacting device to another pole of thevoltage source and to the rear contact; applying a voltage with thevoltage source directed contrary to a forward direction of the siliconsolar cell that is less than a breakdown voltage of the silicon solarcell; and while applying the voltage, guiding a light source over thesilicon solar cell, thereby illuminating a section of a subsection ofthe silicon solar cell and thus inducing a current flow in thesubsection.
 26. The process of claim 25, wherein the current flowrelative to the section has a current density of 200 A/cm² to 20,000A/cm² and acts on the subsection for 10 ns to 10 ms.
 27. The process ofclaim 25, wherein the light source is a laser, a light-emitting diode,or a flash lamp.
 28. The process of claim 25, wherein the light sourceemits radiation with a wavelength in a range from 400 nm to 1500 nm. 29.The process of claim 25, wherein the light source is guided directlynext to contact fingers of the contact grid.
 30. A process for improvingan ohmic-contact behavior between a contact grid and an emitter layer ina silicon solar cell comprising: providing the silicon solar cell havingthe emitter layer, the contact grid, and a rear contact; electricallyconnecting the contact grid to one pole of a voltage source;electrically connecting a contacting device to another pole of thevoltage source and to the rear contact; applying a voltage with thevoltage source directed contrary to a forward direction of the siliconsolar cell that is less than a breakdown voltage of the silicon solarcell; and while applying the voltage, illuminating a section of asubsection of the silicon solar cell by a light source thereby inducinga current flow in the subsection.